Automotive vehicle seat insert

ABSTRACT

There is disclosed an insert suitable for use within a seating system of an automotive vehicle.

CLAIM OF PRIORITY

This application is a continuation of U.S. application Ser. No.12/856,883, filed Aug. 16, 2010, now U.S. Pat. No. 7,971,931, which is acontinuation of U.S. patent application Ser. No. 12/732,534, filed Mar.26, 2010, which is a continuation of Ser. No. 12/354,191, filed Jan. 15,2009, now U.S. Pat. No. 7,735,932, which is a continuation of Ser. No.11/464,859, filed Aug. 16, 2006, now U.S. Pat. No. 7,478,869, which is anon-provisional of application number 60/709,686, filed Aug. 19, 2005,which is a non-provisional of application number 60/787,363, filed Mar.30, 2006, the contents of which are hereby incorporated by reference intheir entirety.

FIELD OF THE INVENTION

The present invention relates generally to automotive vehicle seats, andmore particularly to an insert for providing heating, cooling,ventilation or a combination thereof to a seat of an automotive vehicle.

BACKGROUND OF THE INVENTION

For many years the transportation industry has been concerned withdesigning seats for automotive vehicles that provide added comfort tooccupants in the seats. Such comfort can be enhanced by providingheating, ventilation, cooling or a combination thereof to the seatsand/or the occupant of the seats.

More recently, industry began to design inserts that can be assembled toseats for at least assign in providing heating, ventilation, cooling ora combination thereof. Examples of such inserts are provided in U.S.Patent Application 2002/0096931 and U.S. Pat. No. 6,893,086 both ofwhich are fully incorporated herein by reference for all purposes.Accordingly the present invention provides an insert for providing addedcomfort to a seat of an automotive vehicle or other seat.

SUMMARY OF THE INVENTION

Accordingly an insert is provided for a seating system. The inserttypically includes a spacer material creating an open space within theinsert and can include at least one sealed edge, a single sealed edge orno sealed edges. The insert can be applied to various different seats byis preferably configured for application to a vehicle seat having a seatcushion and a seat backrest cushion wherein at least one of the seat orthe backrest is ventilated. Each ventilated component should have anair-permeable trim surface at the occupant contact areas of the seatparticularly where the insert is configured to be located beneath thetrim surface of each ventilated component. An air mover is alsotypically in fluid communication with the open space within the insert.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claimsand drawings, of which the following is a brief description:

FIG. 1 is a schematic view of an exemplary seating system according toan aspect of the present invention.

FIG. 2 illustrates exemplary inserts and seat cushions according to anaspect of the present invention.

FIG. 3 illustrates the formation of an exemplary insert according to oneexemplary method of the present invention.

FIG. 4 is a sectional view of a portion of an exemplary laminate heaterin accordance with an aspect of the present invention.

FIG. 5 is a perspective view of an exemplary insert in accordance withan aspect of the present invention.

FIGS. 6 and 7 are sectional views of the exemplary insert of FIG. 5applied to a seat cushion in accordance with an aspect of the presentinvention.

FIG. 8 is a perspective view of an exemplary insert in accordance withan aspect of the present invention.

FIG. 9 is a sectional view of the exemplary insert of FIG. 8 applied toa seat backrest cushion in accordance with an aspect of the presentinvention.

FIGS. 10-12 are sectional views of exemplary attachment techniques forattaching an air mover to an insert according to the present invention.

FIGS. 13A-13C are sectional views of exemplary attachment techniques forattaching an air mover to an insert according to the present invention.

FIG. 14 is a perspective cut-away view of an exemplary seat comfortsystem according to an aspect of the present invention.

FIG. 15 is a perspective cut-away view of an exemplary seat comfortsystem according to an aspect of the present invention.

FIGS. 15A and 15B illustrate further alternative option of seat comfortsystem according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is predicated upon providing an insert suitablefor placement within an automotive vehicle seat to provide heating,cooling, ventilation or a combination thereof to an occupant in theseat. Generally, the insert will define an open space with one or morebarrier materials or barrier layers that substantially enclose of spacermaterial and/or cooperatively substantially enclose a spacer materialwith other portions of a seat. As used herein, barrier materials orbarrier layers are materials or layers that are substantiallyimpermeable to fluid flow. Such barrier materials or layers willtypically include one or more openings in fluid communication with theopen space such that fluid and particularly air can flow through the oneor more openings and the open space. Preferably, although not required,the insert will include a plurality of holes extending through thebarrier material or layer such that the insert can distribute air to asubstantial portion of a seating surface or pull air from about asubstantial portion of a seating surface.

Referring to FIG. 1 there is illustrated a seating system 10 accordingto the present invention. The seating system 10 includes a seat 12 witha backrest cushion 14 and a seat cushion 16. The system 10 can includeone or more inserts and can include one or more air movers. As shown,one insert 20 overlays the backrest cushion 14 and one insert 22overlays the seat cushion 16. The system 10 is also shown to include afirst air mover 26 in fluid communication with the insert 20 over thebackrest cushion 14 and a second air mover 28 in fluid communicationwith the insert 22 over the seat cushion 16.

For providing ventilation to a seat or seat occupant, the one or moreair movers will typically be configured to move air through the openspace within an insert and past and/or through a trim layer (e.g.,leather covering) of a seat. The one or more air movers can beconfigured to pull air past or through the trim layer followed bypulling air through the open space within the insert. Alternatively, theone or more air movers can be configured to push air through the openspace of the insert and past or through the trim layer.

Generally, the one or more air movers can be in fluid communication withthe inserts using a variety of techniques. As one example, the insertitself may be configured to form a tubular structure in fluidcommunication with the open space of the insert wherein the tubularstructure has an opening that can extend to and be placed in fluidcommunication with the air mover. As another example, a separate tubularstructure may be employed to extend between the one or more air moversand the one or more inserts for providing fluid communicationtherebetween. Such tubular structures can extend through the seat orbackrest cushion, around the seat or backrest cushion and/or between theseat cushion and the backrest cushion.

In one aspect the tongue or extension of the insert is a tail portionconnected to the main sitting portion of the insert. The tail portionwill typically have a width that is less than the rest of the insert,however this is not necessarily the case and the width of the tailportion may vary over its length, as seen in U.S. Pat. No. 6,840,576. Inone embodiment, the tail portion extends from an edge of the mainportion of the insert, such that it is co-planar with the rest of theinsert (at least at some point during it manufacture or transport). Inanother embodiment, the tail portion protrudes from the underside of theinsert. The tail portion may share a single piece of spacer materialand/or the other layers of the insert with the main portion and beintegrally formed with the main portion as in the previous embodiment,but separate materials may also be utilized. Forming the protruding tailportion may include sealing a portion of the barrier layer onto itselfto create a sealed edge of the main portion, thus, having the tailportion located next to, but separate from, the sealed edge. Where asingle sheet of barrier material is used for both the topside of themain portion and the tail portion. the forming may also include sealinga portion of the barrier layer onto itself to create a sealed crease inthe barrier layer that effectively operates as a sealed edge of theinsert.

For providing heat, an insert according to the present invention caninclude a heater located upon the insert. For example, a heater layercomprised of electric elements and particularly heating elements (e.g.,metal or carbon fiber wires) laminated or otherwise attached to asubstrate may be attached (e.g., laminated) to the insert.Alternatively, the heating elements can be attached directly to abarrier layer or barrier material of the insert or, alternatively, canbe attached to other portions of the insert. It is also contemplatedthat electric elements such as thermoelectric elements may be employedin the same manner as the heating elements, but may be used forproviding heating or cooling to the seating system or an occupanttherein.

For providing cooling, air from or to the one or more air movers may becooled using a variety of cooling devices. As one example,thermoelectric devices may be integrally incorporated with or may beoperationally connected to the one or more air movers for cooling airthat is being pushed into the one or more inserts. As an alternative,air from the HVAC (heating, ventilation and cooling) system of anautomotive vehicle may be channeled or guided to the one or moreinserts.

Openings (e.g., through-holes or perforations) on a forward or uppersurface of the insert may be arranged to facilitate even air flow to orfrom the occupant or trim surface. In one embodiment, perforationslocated proximate to the air mover generally have a smallercross-sectional area than perforation located further from the airmover. By increasing the cross-section area of the perforations asdistance from the air mover increase, the air flow through theperforation may be equalized. Alternately, the perforations may begroups by their distance from the air mover, such that a group proximateto the air mover has a smaller total cross-sectional area than a groupfurther from the air mover, as illustrated in U.S. Pat. No. 6,869,140,incorporated by reference.

In addition, the perforations may be arranged to direct air flow toparticular locations on the forward or upper surface of the insert. Forexample, the perforations may be formed in a V pattern that generallycorresponds to the occupant's body on the seat. In this way, air flowmay be directed to or from the occupant in an efficient manner. Inaddition, perforations may be placed such that inserts in the bolstersof the cushion, whether behind the knees or at the thighs of theoccupant, provide directed air flow to these portions of the occupant.

The insert may include a tongue, as described in U.S. Pat. No.6,840,576, or an extension as described in U.S. Pat. No. 6,893,086, bothincorporated by reference. In the alternative, no tongue or extension isutilized. Rather, one or more conduits that do not include spacer mayfluidity connect the air mover to the insert. The conduit may attach tothe insert in similar locations as the tongue or extension. In thealternative, the conduit may facilitate fluid communication between theunderside of the insert and the air mover. The conduit may directlyconnect the air mover to the insert or the conduit may connect to thecushion which in turn fluidly communicates with the underside of theinsert. The cushion may include a conduit or other through hole in thecushion material. The cushion preferably includes an air impermeablecoating or lining. Multiple conduits or through holes may be utilized toprovide circulation or recirculation of air through the insert, cushionor vehicle cabin. The cushion may include an inset or cavity to housethe air mover on the underside or in the middle of the cushion.

In another embodiment, the air mover may be located locally to theinsert, such the inlet or outlet of the air mover is attached oradjacent to the insert. In one aspect, the air mover may be locatedunderneath the insert in the cushion. In another aspect, the air moveris located such that its inlet or outlet is adjacent to an edge of theinsert such that the air mover and insert are relatively in the sameplane. In either aspect, the air mover may be attached to the cushionthrough any of the mechanisms previously discussed to attach the insertto the seat, such as with an adhesive, a mechanical fastener, etc. Forexample, the air mover may be held to the cushion or insert by hook andloop fastener, through snap fit attachments to the cushion or insert. Inthe alternative, brackets may be molded into the cushion such that theair mover is snapped, slid or otherwise secured to the brackets. In thealternative, the cushion may include one or more wires (e.g. a wiremesh) to which the air mover may be attached, such through cable tie oradditional wires. Preferred attachments mechanisms include those that donot transmit or amplify vibration or noise from the air mover to theseat or passenger compartment.

In one embodiment, the cushion includes an inset or cavity which housesthe air mover. By locating the air mover locally to the insert, assemblyof the system may be simplified. Additional conduits or through holes inthe cushion material provide fluid communication to inlet/outlet of theair mover that is not attached or adjacent to the insert. For example,if the air mover is located underneath the insert in a cavity in thecushion and the system draws air such that the air mover inlet isadjacent to the insert, a conduit or through hole may connect the outletof the air mover to the underside of the seat to provide an exhaustlocation for the air mover.

In one embodiment, the controller and an air mover are combined into asingle housing, thus easing installation and reducing materials cost.The controller in such a combination may control the entire system suchany heating element, thermoelectric devices or other air movers.Alternately, the controller combine with the air mover may act as aslave to a separate master controller. In one aspect, the slavecontroller may take over operation of the entire system should themaster controller fail.

In one embodiment, the controller may be separate from the air mover inits own housing, whether connected to the air mover by a wiring harnessor connect to a common platform with the air mover. Separating thecontroller from the air mover may simplify the construction of thehousing for each as well reduce the chance of interference between theair mover and the controller and may allow for improved cushionflexibility.

In one embodiment, the noise produced by operation of the air mover isabated. In one aspect, the housing of the air mover comprises a doublewall with a space between the walls. Air in the space would act as noiseinsulation. Besides air, other noise abatement materials (e.g. foams)may be used in the space to increase noise abatement. In addition, noiseabatement materials may be included on the interior or exterior of theair mover housing. In one aspect, the air mover is encased in a noiseabatement foam with connection points for an inlet, an outlet and anynecessary electronics (e.g. the controller or sensors). By encasing theair mover in foam, a modular package is created that simply needs to beincorporated into the over all system. As discussed above, the air movermay be seated in an inset or cavity of the cushion. If the cushion isfoam, this would act as a noise abatement material to reduce air movernoise and vibration.

In addition to insulation, other noise abatement techniques may beutilized. A muffler may be attached to the outlet of the air mover. Themuffler may include a series of baffles or other devices on it interiorto absorb noise without seriously impeding air flow through the system.Alternately, the muffler is merely a length of tubing or conduit coveredin noise abatement material (e.g. foam).

In one embodiment, the insert is an edge sealed insert such that theperiphery of the bag has been sealed to form an air impermeable barrier.Edge sealing may be accomplished through the use of an adhesive (e.g. apressure sensitive adhesive), IR, RF or ultrasonic welding. In anotherembodiment less than the entire periphery of the insert is sealed. Forexample, the periphery is of the insert is sealed except for thelocation of attachment for the air mover or the conduit connecting theair mover to the insert.

As discussed above, the cushion may include one or more through holes toaccommodate other components in the system. In addition, other throughholes may be useful for attaching the trim cover to the cushion fromunderneath (e.g. U.S. Pat. No. 6,003,950) or for routing the tongue orextension through the cushion to the underside or rear side of the seat.

In one embodiment, the insert has a seal that extends along a segment ofinsert without extending about the entire periphery of the insert. Forexample such a seal could extend substantially continuously one along aline segment or an arc. Such a seal can extend along a length or widthof the insert. Forming such an insert could be accomplished according toa variety of techniques. As one example, a bag (e.g., a polymeric orthermoplastic bag) having an opening is provided, a spacer material isthen inserted in the bag and the opening of the bag is then sealed(e.g., melt sealed, adhesively sealed, sewn, combinations thereof or thelike) for forming one of the aforecdescribed seals.

The system of the present invention also contemplates a seat or backrestcushion that includes one or more (e.g., 2, 3, 4, 5 or more) openings(e.g., ducts) extending therethrough. Such openings will typically be influid communication with the one or more air movers. In this manner, theseat or backrest cushions can act as a manifold for providing air to aninsert overlaying the cushion. The insert in this situation can includesmultiple openings corresponding to the openings of cushion or have agenerally open portion to provide fluid communication between theinsert, the openings of the cushion and the one or more air movers.

In another embodiment, instead of or in addition to the inclusion of aperipheral seal (and any attendant sealed edge), the insert is sealedalong one or more seams that are located on a bottom surface of theinsert, such as is shown in FIG. 2. Using such approach, it may be alsopossible to secure the insert into a seat cushion, by providing achannel in the cushion adapted to receive the seam. The channels may beconfigured to include a tether for attaching to the insert, a snap forsnap fitting the insert to the cushion, an adhesive into which theinsert is placed and that can be hardened or cured with the insertsecured in place, any combination thereof, or otherwise. Any of themechanical or adhesive fasteners discussed below may be used to attachthe insert into the channel (e.g. hook and loop fastener, Dennison tags,staples, etc.). The seam itself can be formed using any approachdisclosed herein for sealing peripheral edges. It is also possible thatthe seam may be formed by stitching, stapling or some other mechanicalattachment. If so, a seal may be formed, for example, by running theseam into an adhesive bead disposed in the channel of the cushion. Inthis manner, both sealing of the insert and attachment of the insert tothe cushion can be accomplished by the use of the adhesive.

Any of a number of alternative approaches may be employed for securinginserts and other components relative to each other and beneath a trimcover. Of course, one possible approach is to secure an insert or acomponent (e.g., a heater layer, a reticulated foam or some otherspacer, or a combination thereof) directly to the trim cover, whether bysewing, by adhesive, by fastening (e.g., by use of a staple, a snap, ahook and loop fastener, or otherwise), or any combination thereof. It isalso possible for example to keep components or the insert separate fromthe trim cover, but still maintain stability beneath the trim cover,such as by attaching the insert any component, or a combination thereof,by a fastener (e.g., a staple, a snap, a hook and loop fastener, orotherwise) to another component (e.g. the seat cover), to the seatcushion (e.g., by attachment directly to the foam), or both. Forexample, one possible approach is the use of a strip, strap, cable,filament, yarn, staple, stitching, cable-tie, tether or some otherfastener, and particularly fasteners made of a molded, drawn or extrudedplastic, such as a polyamide, an aramid (e.g., Kevlar®), a polyurethane,or the like. Other materials may also be employed in the fasteners suchas metal (e.g., stainless steel wire, copper staples, or otherwise),carbon fiber, or the like. One possible approach is to employ a fastenerthat has enlarged ends (e.g. barbs, wings or anchors) relative to athinned central section, the enlarged ends providing additional loaddistribution area, and/or for resisting pull through relative to theattached parts. Examples of fasteners that may be employed are thosethat are secured by hand using a hand attachment gun, by using asemi-automated or even an automated attachment machine (e.g., a machineas employed for conventional tag attachment). Illustrative commercialproducts suitable for use as fasteners include those available (e.g.,through Avery Dennison) under the designations MicroPin™, MicroTach™,Swiftach® Paddle Fasteners; T-End® Fasteners; Hook-Tach® Fasteners,Secur-a-Tach® Loop Fasteners; Secur-a-Tie®; Tag Fast™ Double PaddleFasteners, and the generic equivalents of the foregoing. In anotheraspect, fasteners or portions there of may be held or anchored withinthe cushion such that the insert may be then attached to the fastenerprotruding from the cushion. For example, during formation of thecushion, clips, slides screws, or bolts may be molded into the cushion.The appropriate clasp or receiver on the insert may then be used toattach the insert to the cushion. As with other fasteners, metal,plastic, carbon fiber or materials may be used for the anchoredfasteners.

The attachment may occur by an assembler at the time of assembling thesystem into a seat, at the time of manufacturing the components of thesystem prior to assembly into the seat, at the time of fabricating thetrim cover, or any combination. In one embodiment, the attachment of theinsert occurs during the formation of the seat cushion, such that theinsert is molded to the seat cushion. Alternately, attachment occurs bysewing the insert or portions thereof to the cushion.

It may also be possible to integrally form a neck in the insert that canfunction to penetrate through an opening in an upper surface of a seatcushion. The resulting assembly this would include the insert in fluidcommunication with an air mover, e.g., by a direct connection with theair mover, or by being spaced apart from the air mover.

Another possible approach for making an insert according to the presentinvention, an example of which is shown in FIG. 3, is to provide aflexible sheet (e.g., a thermoplastic sheet). A plurality ofprotuberances are formed, attached or otherwise provided to one surfaceof the sheet. The protuberances may be generally straight, they may becurled, or a combination thereof. The protuberances may be of generallythe same size, a different size or a combination thereof. Theprotuberances may comprise fibres, solid rods, hollow rods (e.g., with aclosed distal end), elongated ribs, or any combination thereof. Theprotuberances may be integrally manufactured with the sheet,manufactured separate from the sheet and then attached to the sheet, ora combination thereof. The sheet is also made to include a perforatedregion, that has a plurality of perforations for passage of airtherethrough (from being drawn, blown or a combination). Perforationscan be made during the initial fabrication of the sheet, or during asubsequent step (e.g., before, during or after any step of providingprotuberances to the sheet). The sheet also will include at least onegenerally continuous region that is generally not perforated (exceptpossibly to include one or a small number of ports for allowing fluidcommunication with the air mover). Preferably the generally continuousregion adjoins the perforated region. In this manner, the generallycontinuous region and the perforated region can be folded upon eachother and the sheet thereafter sealed together (e.g., by adhesive, byweld, by fastener or other mechanical attachment, or any combinationthereof), so that the generally continuous region and the perforatedregion are substantially opposite each other. The protuberances therebyeffectively form a spacer. As will be appreciated, in one embodiment(e.g., where the protuberances are elongated ribs) such a process lendsitself well to manufacture of the sheet and protuberancessimultaneously, such as by an extrusion or molding process.

According to one embodiment, the insert may be formed by insert moldinga barrier material about a spacer material. Formation of the insert willgenerally include insertion of the spacer into a molding machine,closure of the molding machine about the layer and molding (e.g.,compression molding, blow molding, injection molding or the like) thebarrier material about the spacer material such that the spacer layermaintains internal open space that become substantially surrounded bythe barrier material. Openings (e.g., through-holes) may be formed inthe surround barrier material of the insert by directly molding theopenings into the barrier material or by forming such openings in asubsequent cutting operation. Many different spacer materials may beemployed as disclosed herein. As an example, one preferred material issold under the tradename 3MESH® and is commercially available fromMüller Textil GmbH, Germany or Müller Textiles, Inc., Rhode Island, USA.According to one preferred embodiment, a layer of the spacer material isplaced within an blow molding machine and a polymeric barrier materialis blow molded about the periphery of the layer such that the polymericbarrier material adheres to the spacer material at its periphery whilemaintaining internal open space within the spacer that is substantiallyenclosed by the polymeric barrier material. Any necessary perforationsin the polymeric barrier may be formed during the molding process.Alternately, perforations in the polymeric barrier may be made bycutting with a knife, laser, a die or other suitable cutting tool orpoint specific removal of the polymeric barrier by degrading the barrierwith energy (e.g. a laser, RF or infrared energy).

In one embodiment the spacer material is not affixed to the othercomponents of the insert. The space may be held in place by sandwichingthe spacer between other components e.g. two barrier layers or between abarrier layer and a cushion. In a preferred embodiment, the spacer isattached or connected to at least one other component of the insert orthe seat (e.g. the cushion). As discussed previously, adhesives may beused to combine the components. In another aspect, the spacer may beheat staked or welded (e.g. spot welded) to one or more of the barrierlayers or cushion. Heat staking is understood by a skilled artisan andmay involve the application of a heated tip to a thermoplastic materialto cause localize melting, which in turn would assist in attaching thespace to other components. In addition to localize attachment providedby heat staking, localized and area attachment may be provided bywelding. Welding may be accomplished through the use of infrared, radiofrequency, ultrasonic, laser light, UV light or other electromagneticenergy to cause a physical or chemical bonding of the spacer to theother components. In addition, mechanical fasteners, as previouslydescribed, may also be used to attach the spacer to the barrier layer orcushion.

For the portions of the barrier layers, cushion or other components thatare generally parallel to the occupant surface of the seat, the spaceris preferably attached without the use of adhesive, but with themechanisms discussed above (e.g. staking welding, mechanical fasteners,etc). For portions of the barrier layers, cushion or other componentsthat generally perpendicular to the occupant surface of the seat, thespacer is preferably attached with an adhesive, with the mechanismsdiscussed above or both.

The system for heating, cooling and/or ventilating the seat may includemultiple inserts, multiple air movers, and/or multiple controllers. Foran original equipment manufacturer (OEM) system, the system preferablyincludes an insert for each of the seat cushion and the backrestcushion, as well as an air mover for each insert. A single controllermay be used to provide operational control to both air movers.Alternately, individual controllers are utilized for each air mover. Inaddition, multiple thermoelectric devices may be used (e.g. one or morefor each insert). For an aftermarket system, the system preferablyincludes a single insert for both the seat cushion and the backrestcushion. In such an embodiment, a single air mover and a singlecontroller may be used, although it is possible to utilize multiple airmovers with a single insert.

According to another embodiment, an insert is formed of a single barrierlayer that is secured (e.g., with an adhesive or otherwise) to a layerof spacer material such that the barrier layer overlays the layer ofspacer material. In such an embodiment, it is preferable for the cushionto which the insert is applied to have an inset or cavity for receivingthe layer of spacer material. The inset will typically have depth that,upon insertion of the barrier layer within the inset, locates thebarrier layer near (e.g., within 1 cm, 0.5 cm, 0.2 cm) flush with aportion or surface of the cushion that surrounds the inset. The insetmay be formed at the time the cushion is created (e.g. molded) or it maybe formed later by cutting away or otherwise carving out cushionmaterial. It is generally contemplated that the barrier layer may beadditionally secured (e.g., adhesively sealed, sewn or otherwisemechanical attached) to the cushion. For example, the barrier layer mayinclude a peripheral edge that extends beyond the spacer layer suchthat, upon insertion of the spacer layer within the inset of thecushion, the peripheral edge overlays the portion of the cushion thatsurrounds the inset. Advantageously, the peripheral edge can include anadhesive that can be adhered to the surrounding portion of the cushionfor sealing the peripheral edge to the barrier layer of the surroundingportion of the cushion. Such adhesive may be covered by release materialthat is coextensive with the peripheral edge such that the releasematerial can be peeled away just prior to location of the spacer layerwithin the inset and adhesion of the peripheral edge to the cushion.Sewing or mechanical fasteners may be used alone or in addition toadhesives to secure the peripheral edge of the barrier layer to thecushion. Alternately, the spacer having the barrier layer with theperipheral each may be molded to the cushion during formation orcreation of the cushion. In this aspect, the inset or cavity of thecushion is formed to match the insert. In any embodiment where a barrierlayer does not separate the cushion from the spacer, an air impermeablecoating or lining on the cushion is preferred, but not required, lessthe absorption of heat or cold by the cushion.

In one embodiment, a particularly desirable system for heating andventilating and/or cooling seats is formed according to the presentinvention by integration of a polymer resistive heater or, moreparticularly, a polymer film resistive heater. Such a heater willtypically include a substrate provided a panel or layer with one or moreresistive polymer layers (e.g., films) that are coextensive with asubstantial portion or the entirety of a surface of the substrate. Suchresistive polymer layers are often formed of polymer materials (e.g.,polymer thick film materials) that create heat upon the flowing of anelectrical current through the material based upon their resistance tothe current. These materials can be positive temperature coefficient(PTC) materials, negative temperature coefficient (NTC) materials,constant temperature coefficient (CTC) materials, combinations thereofor the like. It is also contemplated that these materials can beresistive by virtue of materials within the polymeric material such asmetals (e.g., copper, nickel, silver, combinations thereof or the like),carbon materials (e.g., carbon black) or other conductive materials. Asyet another alternative, the resistive layer may be entirely orsubstantially entirely formed of these conductive materials. Thesubstrate can be formed of a variety of materials include fabrics, wovenmaterials, rigid materials, flexible materials, combinations thereof orthe like. In one preferred embodiment, the substrate is form of apolymeric or plastic film that typically includes or is formedsubstantially entirely of polyurethane (e.g., thermoplastic or thermosetpolyurethane), polyethylene, polypropylene, polystyrene. polyamide,polyimide, combinations thereof or the like.

Preferably, the polymer resistive heaters are air permeable when used inconjunction with ventilating and/or cooling systems, although notrequired. The heaters may include one or more openings (e.g.,through-holes, slits or the like) for allowing air to flow therethrough.Alternatively, the substrate could be formed of an air permeablematerial such as a fabric for allowing air to flow through the heater.As another alternative or addition, the heater can be non-permeable butlocated so as to avoid restricting air flow.

Generally such heaters are constructed to have multiple layers and caninclude, in addition to the substrate layer and conductive polymerlayer, also can include additional polymers film layers, protectivelayers (e.g., layers of gauze, elastomeric material or other protectivematerials, adhesive layers, release layers, combinations thereof or thelike. FIG. 4 illustrates a section of one desirable laminate heater 50that includes a resistive layer 52 as described. Preferably, theresistive layer 52 is formed of a polymeric material with a conductivemetal (e.g., silver) dispersed throughout the material, although notrequired. Additionally, the heater 50 includes a first polymer filmlayer 54 and a second polymer film layer 56, either or both of which,may be considered the substrate. As shown, resistive layer 52 directlycontacts that second polymer film layer. The heater 50 also includes alayer 60 of adhesive such that the resistive layer 52 is disposed orsandwiched between the adhesive layer and the substrate or one or moreof the polymer film layers 54, 56. A release layer 62 additionallyoverlays the adhesive layer 60.

In addition to the above, these polymer conductive heaters can alsoinclude buss bars, electrical connectors and electrical busses or wires.In the typical heater, two or more buss bars are spaced apart and areelectrically in communication with each other through the polymerconductive material. Each of the two or more buss bars are alsotypically in electrical communication with electrical connectors thatconnects the heater to a power source through the electrical busses orwires.

A heater, particularly a heater having a polymer resistive layer, can beintegrated with a seating ventilation insert according to a variety oftechniques and in a variety of configurations. Any of the insertsdiscussed herein may be combined with a heater have a polymer resistivelayer. As an example, FIGS. 5-8 show exemplary ventilation inserts 70 towhich such heaters attached. The inserts 70 include a forward layer 76(i.e., a layer configured to be closer to a seat occupant), a rearwardlayer 78 and spacer layer 80. Of course, the insert 70 may include feweror greater layers and each of the layers 76, 78, 80 may include multiplelayers or sub-layers.

Generally, the heater 74 is formed as one or more layers and isintegrated with, placed between and/or attached to one or a combinationof these layers 76, 78, 80. The heater can be secured to these layerswith a variety of attachments such as adhesive, fasteners, mechanicalinterlocks (which may be integral with layers, the heater or both),welds (e.g., welds formed from radio frequency welding, vibrationwelding, heat staking, combinations thereof or the like), meltattachments or seals (e.g., attachments formed by melting a portion orlayer of the insert and/or a portion or layer of the heater such thatone or both melt and attach to the other), combinations thereof or thelike. When used, suitable adhesives can include acrylic, urethane,epoxy, one component, two component, radiation cured, moisture or aircured, cure-on-demand adhesives, combinations thereof or the like.

In one embodiment, the heater layer includes a release layer covering anadhesive layer and the release layer may be removed followed bycontacting and adhering the adhesive layer to one of the layers of theventilation insert, typically after the forward layer has been attachedto the spacer layer, the rearward layer or both. In another embodiment,the heater layer is laminated (e.g., by adhesive securing) to theforward layer or the spacer layer (typically in a belt or stationarylamination process) prior to attachment of the forward layer, the spacerlayer or both. It is also contemplated that the heater layer could beattached to (e.g., adhered to) the forward layer, the spacer layer orboth with an adhesive coating and pressure process.

As examples, Inserts can have a forward layer, a rearward layer and aspacer layer intermediate the forward and rearward layers. In FIGS. 5-9,a heater layer 74 has been attached to an outer surface of the forwardlayer 76 (e.g., a surface of a protective or barrier layer) of theinsert 70. As an alternative, however, a heater layer can be attached toan inner surface of the forward layer (e.g., a surface of a barrierlayer of the forward layer), the spacer material, or both. It is alsocontemplated that a heater layer can be located between and attached toand/or located between a protective sub-layer and/or a barrier sub-layerof the forward layer of the insert. As used herein, a protective layeror sub-layer is intended to mean any layer that functions at leastpartially to reduce friction between at least one layer or sub-layer ofthe insert and another surface (e.g., a surface of a seat or theinsert). Examples of typical protective layers include, withoutlimitation, fibrous layers (e.g., fleece, mesh or gauze layers),elastomeric layers or the like. It is also contemplated that on or morelayers of the forward layer may act as the substrate of the heaterlayer.

It can also be desirable, for heating and ventilation inserts of thepresent invention, to attach one or more air movers (e.g., fans) to theinserts using fan assemblies and attachment techniques that providedesirable characteristics such as flexibility, low cost, robustconstruction and the like. Moreover, it can be particularly desirable toprovide fan assemblies and attachment techniques that are well suited towithstand and do not interfere with assembly of the seat of anautomotive vehicle.

Typically, as illustrated in FIGS. 13A-13C, an air mover 100 includes anair moving member, which is shown and referred to herein as a fan 102,and a housing 104 at least partially or substantially entirely surroundthe fan 102. Of course, other air moving members may be used such as apump. Various attachments such as an adhesive, one or more mechanicalattachment, interference fits, hook an loop fasteners, magnets,combinations thereof or the like may be employed to attach the airmovers and particularly the housing of the air movers to portions of theinserts such as barrier layers (e.g., forward or rearward layersincluding barrier sub-layers), protective layers, spacers materials,combinations thereof or the like.

In FIG. 13A, an air mover 100 is attached to an outer surface 110 of alayer 112, particularly a forward or rearward layer 112, of an insert114. Preferably, the housing 104 of the air mover 100 is secured to thesurface with an adhesive, one or more mechanical fasteners or both. InFIG. 13B, an air mover 100 is attached to an insert 114, at least inpart, by interference fitting a flange 108 (e.g., a circumferentialflange) of the air mover 100 between a layer 110, particularly a forwardor rearward layer 110, of the insert 114 and a mass, particularly alayer 116, of spacer material of the insert 114. Of course, adhesives oradditional mechanical fasteners may also attach the air mover 100 to oneor both of the layers 110, 116. In FIG. 13C, an air mover 100 isattached to an insert 114, at least in part, by interference fitting aflange 108 (e.g., a circumferential flange) of the air mover 100 betweena barrier layer 120 of the insert 114 and a protective layer 122 of theinsert 114, both of which are preferably sub-layers of a forward orrearward layer of the insert 114. Of course, adhesives or additionalmechanical fasteners may also attach the air mover 100 to one or both ofthe layers 120, 122.

As another preferred attachment of the air mover to the insert, it iscontemplated that the housing of the air mover may be configured tomechanically or otherwise engage a connector member. As one example,FIG. 10 shows an air mover 130 having an engagement portion, shown as anannular wall 132 of a housing 133, that compression fits with anengagement portion, shown as an annular wall 134, of a connector member136 and, at least in the embodiment shown, sandwiches a portion 140(e.g., an annular portion) of a layer 142 (e.g., a forward or rearwardlayer) of the insert therebetween. As shown, the engagement portion 134of the connector member 136 is smaller (e.g. has a smallercircumference) than the engagement portion 132 of the housing 133 and iscompression fit within the portion 132 of the housing 133, although thereverse may also be done as well.

In addition or as alternative to compression fitting, the engagementportions of the housing and/or connector member may include one or moremechanical interlock features. In FIG. 11, one of the portions 150, 152includes a protrusion 156 (e.g., an annular or semi-annular protrusion)that is configured to extend into one or more openings 158 (e.g., acavity) upon location of a housing 160 adjacent the connector member 162thereby interlocking the two together. In FIG. 12, one or moreprotrusions 166 are generally hook shaped and designed to extend throughthe one or more openings 168 (e.g., through-holes) upon location of thehousing 170 adjacent the connector member 172 thereby interlocking thetwo together.

In any of the embodiments, it is generally contemplated that the airmover housing or parts thereof could be made of a variety of materialincluding, without limitation, metals and plastics. In one preferredembodiment, however, a portion or substantially the entirety of thehousing of the air mover is formed of an elastomeric or rubber materialsuch as neoprene rubber, nitrile rubber, butadiene rubber, isoprenerubber, butylene rubber, urethane rubber, chloroprene rubber, silicone,combinations thereof or the like.

With reference to FIG. 13, it is contemplated that a portion or thesubstantial entirety of a body portion 176 (e.g., annular body wall) ofthe housing 104 may be formed of an elastomeric material. Additionallyor alternatively, a portion or the substantial entirety of a flangeportion 108 (e.g., an outwardly extending annular flange wall) of thehousing 104 may formed of an elastomeric material. Advantageously, suchelastomeric materials can provide additional tolerance for compressionor other forces that may be caused by assembly or usage of seatincluding the ventilation and/or heating systems of the presentinvention.

Generally, it is contemplated that one fan may be attached to an insertor multiple fans may be attached to an insert and the fans may havevariable sizes and configurations. In one preferred embodiment, theheating and/or ventilation system of the present invention will includeone or multiple fans connected to an insert at predetermined locationssuch that those fan(s) are positioned within openings (e.g., cavities,through-holes or combinations thereof) of a cushion (e.g., a foamcushion) of a seat (e.g., an automotive seat) upon assembly of theinsert to the seat. Examples of such configuration are shown in theautomotive seat back 180 and insert 70 of FIGS. 8 and 9 and theautomotive seat cushion 182 and insert 70 of FIGS. 5-9.

Another desirable embodiment of the present invention is depicted inFIG. 14. As can be seen, a system 200 is illustrated to have an insert202 overlaying a seat cushion 204 and the insert is in fluidcommunication with an air mover. For heating, a plurality (e.g., 2, 3, 4or more) heating pads 205 are disposed upon (e.g., overlay) a forwardlayer 206 of the insert 202.

Each of the heating pads 205 includes one or more electrical terminals208 interconnected by a resistive material 210 and each of the terminalis connected to an energy source (e.g., electrically connected to thebattery of a vehicle). Although the heating pads 205 may be selectedfrom a variety of heaters, it is preferred that the heating pads 205 areformed as resistive polymer heaters as discussed herein or otherwise.Thus, the heating pads 205 may be attached to the forward layer 206 orother portion of the insert 202 with any of the techniques discussedherein such as adhesives, mechanical fasteners or the like.

As shown, the forward layer 206 of the insert 202 includes multipleopenings 214 for promoting fluid communication between a surface of aseat and the insert 202 as is describe herein. Preferably, although notrequired, the pads 205 are disposed on the forward layer 206 away fromthe openings 214 such that the pads 205 avoid substantial restriction ofair flow through the openings 214.

Also shown, busses or wires 220 can extend between and connect theterminals 208 of the pads 205 for allowing the flow of electricalcurrent therethrough. In a preferred embodiment, the busses or wires 220are meandering (e.g., travel is a side to side manner, zig-zag manner orthe like) as they extend from one terminal 208 to others. Such indirectextension can accommodate stretching of the insert and/or movement ofthe terminals 208 toward and/or away from each other. It is alsocontemplated that the busses 220 can be located outside the rest of theinsert or may extend from one terminal to another at least partiallyinside the layers (e.g., between the forward layer and the spacer and/orrearward layer) of the insert.

As additional or alternative aspect of the present invention, it iscontemplated that a portion (e.g., a flange) of the air mover housingcan overlap a seat cushion for supporting the air mover. In such anembodiment, the air mover may be attached (e.g., adhesively secured) tothe spacer material or may only be located adjacent an in fluidcommunication with the spacer material of an insert.

With reference to FIG. 15, a system 250 is illustrated to include a seatinsert 252 located over a seat cushion 254. The system 250 includes anair mover 258 with a fan 260 and a housing 262. As shown, the air moverhousing 262 includes an annular flange 266 that extends outwardly fromthe air mover 258 and is designed to overlap a portion of the seatcushion 254 for supporting the air mover 258. In the particularlyembodiment illustrated, the cushion 254 includes an annular cavity 270for receipt of the flange 266.

The insert 252 includes a bag 274 that has one main opening 276 suitablefor receipt of spacer material 278. As shown, the bag 274 defines aforward barrier layer 280 and a rearward barrier layer 282 and the mainopening 276 is sealed adjacent one side edge of the insert 252 by, forexample, melt sealing, folding over of the bag, adhesive sealing,sewing, combinations thereof or the like. The forward layer 280 includesmultiple openings 286 (e.g., holes or perforations) for fluidcommunication with a trim surface of a seat and the rearward layer 282includes at least one opening 290 for fluid communication with the airmover 258. Optionally, the air mover 258, particularly its housing 262may be secured (e.g., adhesively or otherwise) to the spacer material278.

As further additions or alternatives, and with reference to FIGS. 15Aand 15B, it is contemplated that an insert 294 may be formed by coveringsubstantially only the edges 296 of a spacer material 297 with barrierlayers 298. As shown, barrier layers 298 wrap about edges 296 of thespacer material 297 while leaving substantial body portions (e.g., 30%,50%, 60% or more) of the spacer material 297 uncovered by the barrierlayers.

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1. An apparatus for use on top of a cushion, the top of the cushiondisposed under a trim cover, having an air-permeable trim surface, of aventilated seating system, and including two or more through-holes, theapparatus comprising: a forward layer including a plurality of openingsin fluid communication with the air-permeable trim surface; a rearwardlayer comprising a first material and including at least two openingsand having an inner surface and an outer surface; a spacer materialsandwiched between the forward layer and the rearward layer, creating anopen space within the apparatus; two or more air movers disposed outsideof the rearward layer of the apparatus, each air mover attached to aninner surface of the rearward layer at one of the at least two openingswith an outwardly extending annular flange wall, and in fluidcommunication with the spacer material and the air-permeable trim cover;wherein each of the air mover of the apparatus is dimensioned to fitwithin a cavity created by the two or more through-holes and disposedtherein.
 2. The apparatus according to claim 1, wherein the air moversalso include a controller combined into a housing of the air movers. 3.The apparatus according to claim 1, wherein the outwardly extendingannular flange wall of each of said air movers is adhered to the innersurface of the rearward layer.
 4. The apparatus according to claim 1,wherein the apparatus further comprises a connector member, theconnector member at least partially sandwiching the rearward layer withthe outwardly extending annular flange wall of one of the two or airmovers.
 5. The apparatus according to claim 1, wherein the apparatus isoperationally connected to a thermoelectric element to provide heatingor cooling.
 6. The apparatus according to claim 1 further comprising aheater integrated in the forward layer.
 7. The apparatus according toclaim 6 wherein the heater comprises a positive temperature coefficientmaterial.
 8. The apparatus according to claim 7 wherein the heatercomprises a substrate layer comprising a polymeric film.
 9. Theapparatus according to claim 8 wherein the polymeric film includes oneor more openings for allowing air to flow through the polymeric film.10. The apparatus according to claim 6 wherein the heater comprises atleast one of a metal wire or a carbon wire.
 11. The apparatus accordingto claim 1 wherein the forward layer, the rearward layer, or bothcomprises at least one of a fleece, a mesh or a gauze material.
 12. Theapparatus according to claim 1 wherein the forward layer and therearward layer are sealed about a periphery forming a sealed peripheraledge.
 13. The apparatus according to claim 1 wherein the air movers areeach a fan that is adapted to move air through the insert in a directionthat will push the air through the air-permeable trim surface and towardan occupant.
 14. The apparatus according to claim 1 wherein the airmovers are each a fan that is adapted to move air through the insert ina direction that will pull air through the air-permeable trim surfaceand away from an occupant.